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ONLINE PROCESS SIMULATIONONLINE PROCESS SIMULATIONONLINE, REAL-TIME AND PREDICTIVE PROCESS DATA INTEGRATION WITH CHEMSTATIONS’ SOFTWARE

Nor-Par Online A/S

PLANT2CC/PLANT2CCD INTERFACE

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All the terms below mean exactly the same thing• SCADA = Supervisory Control And Data Acquisition• HMI = Human-Machine Interface• Process Visualization software

• DCS console software• Real Time Database (RTDB)

SCADA/HMI/Visualization/DCS console/RTDB is a class of software that presents data available at DCS (Distributed Control System) or PLC (Programmable Logic Controller) ina form that a human can understand. The plant personnel can also manipulate the settings of DCS/PLC directly from suchSCADA systems, as a modern alternative to a traditional control room.

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Samples of SCADA systemsModern SCADA systems are all Windows-based, run on a PC, and are compatible with Microsoft Excel.

RS ViewRockwellFactory LinkUS Data

Simatic WinCCSiemensAspen Process Explorer

AspenTech

SCSOmronInTouchWonderware

IA SeriesFoxboroPIOil Systems Inc.

PHD, FiXHoneywellFiXIntellution

DCS vendor SCADAIndependent SCADA

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Online, Real-Time and Predictive Process Simulationfrom Nor-Par Online A/S

• PLANT2CC runs online process simulation driven by true production data in CHEMCAD

• PLANT2CCD runs real-time and predictive process simulation driven by true production data in CC-ReACS and/or CC-DCOLUMN

• You need to have a SCADA/HMI/Process Visualization/DCS console/RTDB software compatible with Excel as well as respective Chemstations’ software to use the PLANT2CC/PLANT2CCD solution

WhatSCADA (or)

HMI (or)Visualization (or)DCS Console (or)

Real-Time Databasedoes your Plant use?

Before we continue, let’s have this matter clear

☺

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SCADASCADA/HMI/VISUALIZATION/HMI/VISUALIZATION SYSTEM STRUCTURESYSTEM STRUCTURE

CLIENT

DATASERVER

CONTROLLERHARDWARE

FIELDDEVICES

CONTROLLERHARDWARE

CLIENT

ETHERNET DATA HIGHWAY

DATASERVER

CONTROLLERHARDWARE

FIELDDEVICES

FIELDDEVICES

FIELDBUS

PROCESSMODEL

VALVES & SENSORS

PLC’SDCS

PLANT INFORMATION MANAGEMENT SYSTEMS PIMS

OPC SERVERS

OPERATOR WORKSTATIONS

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OFFLINE DATA HANDLINGOFFLINE DATA HANDLING

DATA OVERLOAD

SCADASCADA/HMI//HMI/VISUALIZATIONVISUALIZATION

INADEQUATE

!! ANALYSISANALYSISHOW DO YOU DO IT?HOW DO YOU DO IT?

UNCERTAINTY

!! DECISIONDECISION

FLIES!!!!FLIES!!!!TIME!!!!TIME!!!!

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CHEMCADCHEMCADThe Process Simulation EngineThe Process Simulation Engine

• Process models (flowsheets) are built and solved in a process simulator. The process simulator works as a mathematical engine for solving mass and heat balances, fluid property and equipment parameter calculations, as well as equipment sizing

• We support the superior process simulation software fromChemstations Inc, which is powerful, easy to use, and has themost modern integration capabilities

• CHEMCAD is Steady State process simulator. CC-ReACS, CC-DCOLUMN and CC-POLYMER are Dynamic process simulators

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SOFTWARE STRUCTURESOFTWARE STRUCTURE

CCCC--ReACSReACS****

Batch ReactorsBatch Reactors

Client’sClient’sSCADASCADASystemSystem

CHEMCADCHEMCAD****

Steady State

CCCC--POLYMERPOLYMER****

Polymer ReactorsCCCC--DCOLUMNDCOLUMN****

Dynamic Column

PLANT2CCPLANT2CC**

PLANT2CCDPLANT2CCD**

*) From Nor-Par Online A/S**) From Chemstations Inc.

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PLANTPLANT2CC2CC(D)(D) SYSTEM ARCHITECTURESYSTEM ARCHITECTURE

CUSTOMER

SCADACLIENT

DATASERVER

CONTR-OLLER

FIELDDEVICES

ETHER NET

1

TC2

3

4 5

67

12

5 6

78 9

10

8 10

TC11

1213341213

15

16

17

18

11

T 300

W 13697 T 138

W 45000

T 138

W 0

T 49

W 45000

T 49

W 13696

T 49

W 31304

T 138

W 45000

T 138

W 45000

Coolant

Heat Transfer Oil Supply

Heat Transfer Oil Return

DYNAMIC PROCESS MODEL:CC-REACS, CC-DCOLUMN

THE PC STEADY STATE PROCESS MODEL: CHEMCAD

NOR-PAR ONLINE A/S

PLA

NT2

CC

PLA

NT2

CC

D

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ONLINE STEADY STATE PROCESS ONLINE STEADY STATE PROCESS OPTIMIZEROPTIMIZER

PLANT2CC AND CHEMCADNORPARONLINEA/S

CUSTOMER

SCADA

SCADA VISUALIZATION MIMIC

PROCESSPLANT

PLANT2CC

CHEMCAD MODEL

SCADASYSTEM

""!!""!!

""!!

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STEADY STATE OR DYNAMICSSTEADY STATE OR DYNAMICSSteady State SCADA integration

" Based on Online Process Simulation principle, modeling the plant behaviorby continuous series of steady state approximations

" Requires least effort to construct and calibrate the flowsheet

" Ideal for economic analysis and online optimization

" Requires CHEMCAD only

" Can only be applied to process units between intermediate and storage tanks

Dynamic SCADA integration

" Based on Real Time or Predictive Dynamic Process Simulation principle

" Takes into account true dynamic behavior of the plant, including equipment size, accumulation, and control system unit operations

" Ideal for troubleshooting, control loop tuning and real time optimization

" Requires CC-ReACS orCC-DCOLUMN

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ONLINE DYNAMIC PRODUCTION OPTIMIZER ONLINE DYNAMIC PRODUCTION OPTIMIZER

1

TC2

3

4 5

67

12

5 6

78 9

10

8 10

TC11

1213341213

15

16

17

18

11

T 300

W 13697 T 138

W 45000

T 138

W 0

T 49

W 45000

T 49

W 13696

T 49

W 31304

T 138

W 45000

T 138

W 45000

Coolant

Heat Transfer Oil Supply

Heat Transfer Oil Return

DYNAMIC PROCESS MODEL

PLANT2CCD

SCADA VISUALIZATION MIMIC

NORPARONLINEA/S

CUSTOMER

SCADA

CC-REACS, CC-DCOLUMN

PROCESS PLANT

PLANT2CCD

CC-ReACSCC-DCOLUMN

SCADA SYSTEM

""!!""!!

""!!

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TRAININGTRAINING & EDUCATION& EDUCATION SIMULATORSIMULATOR

1

TC2

3

4 5

67

12

5 6

78 9

10

8 10

TC11

1213341213

15

16

17

18

11

T 300

W 13697 T 138

W 45000

T 138

W 0

T 49

W 45000

T 49

W 13696

T 49

W 31304

T 138

W 45000

T 138

W 45000

Coolant

Heat Transfer Oil Supply

Heat Transfer Oil Return

NORPARONLINEA/SDEALERS

T & E Simulator Controller/Scenario Database

DYNAMIC PROCESS MODEL

TRAINING SIMULATOR CUSTOM MIMIC

CC-REACS, CC-DCOLUMN

T & E SimulatorController

Scenario Database

CC-ReACSCC-DCOLUMN

SCADAMIMIC

""!!""!!

VIRTUALPLANT

OFFLINEPLANT

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ONLINE SIMULATION BENEFITSONLINE SIMULATION BENEFITS

INTEGRATED PRODUCTION SOLUTIONINTEGRATED PRODUCTION SOLUTION

MONITORING

OPERATIONS

MAINTENANCE

ECONOMIC

TRAINING

DATABASE

Integration with client’s own Production Management System like SAPHISTORY

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MONITORING BENEFITS MONITORING BENEFITS

SCADASYSTEM

INTERFACEPLANT2CC

PROCESS MODEL

CHEMCAD“Virtual Plant”

PROCESSPLANT

Soft sensor (no instrument installed or available)Component composition predictionPrediction of inferred measurements

Estimation of unmeasured process conditionsComponent concentrations in reactorTemperature profiles in reactors and columns

Concentration profiles in the columnsHeat transfer coefficients,fouling,specific heatStudy interactions of dependent variables

Estimation of physical propertiesAll calculated stream properties in CHEMCAD can be returned to Excel for analysis

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OPERATIONAL BENEFITSOPERATIONAL BENEFITSAllows calibration of process modelUsing true data from the productionCalibration of process and control modelsAids prediction of optimum performance

Tool for speeding up troubleshootingPredict the onset of production problemsIdentify problems from SCADA and model historyLearn to start up and shut down the plant for increased safety

Provide help for improving the process modelModel inaccuracy easier to detect and correctOnline optimization based on true dataCost savingsHistorical data

SCADASYSTEM

INTERFACEPLANT2CC

PROCESS MODEL

CHEMCAD“Virtual Plant”

PROCESSPLANT

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MAINTENANCE BENEFITSMAINTENANCE BENEFITS

SCADASYSTEM

INTERFACEPLANT2CC

PROCESS MODEL

CHEMCAD“Virtual Plant”

PROCESSPLANT

Fault diagnosis & Data reconciliationFouling and scaling monitoringCondition monitoring of expensive equipmentInstrument fault diagnosisInstrument calibration frequency

Maintenance planningUse of historical data for process and mechanical maitenance planning, integrated with SAP or other Process Information Management Systems

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TRAININGTRAINING & EDUCATION & EDUCATION BENEFITS BENEFITS

Improve production efficiencySCADA operator interface is identical to real plant modelEngineers understanding of the process enhancedEngineers can study effect of control settingsEngineers can study parameter interactionsDowntime due to operator error reducedLearning start-up and shutdown proceduresConsequences of operator actions to environment(Environmental Impact factors by WAR technology)Improve production safety

Operational plant safety improvedLearning without the consequences of risk/damage

SCADAMimic

T & E S ControllerScenario Database

PROCESS MODEL

CC-ReACSCC-DCOLUMN“Virtual Plant”

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ECONOMIC BENEFITSECONOMIC BENEFITSCapital cost savingsInfer measurements from calibrated modelReduced installed instrumentation

Production cost savingsEconomic calculations based on modelIntegration with SAP systemReducing cost on maintenance, start-up and shutdown

On-line optimizationAdjust process to minimize production cost Optimize plant throughputsBetter control of purity, increasing the product value Better control of emissions and waste from the process, reducing environmental penalties

Sensitivity analysisSensitivity of yields to process changesSensitivity of energy usage to process changes

SCADASYSTEM

INTERFACEPLANT2CC

PROCESS MODEL

CHEMCAD“Virtual Plant”

PROCESSPLANT

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SAVINGSSAVINGSThe savings that can be achieved by using the integration of SCADA with Chemstations software will be result of:

• Running the plant with high quality product, less pollution, and faster using the existing equipment

• Online optimization of the production• Maintaining better product and production

documentation, according to FDA and other procedures/standards

• Reducing the duration and cost of start-up• Limiting shutdowns only to planned ones• Avoiding breakdowns and unpleasant failures• Optimizing, calibration and tuning the control system in

short period of time• Training operators to higher level of understanding

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SAVINGS EXAMPLESAVINGS EXAMPLE

We are talking about substantial savings.

We have a client that makes and operates many 5 kt/y units for on-site production of Chlorine Dioxide. This is one the smallest production capacities at which continuous processes are operated.

This technology was mastered by the client who had been using CHEMCAD and a SCADA system for several years.

Yet, applying the PLANT2CC has brought the client additional savings estimated to $70,000 yearly per each of aforementioned small units.

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We have understood from works we have done under secrecy agreements with some of our clients that:

• For a well operated advanced plant producing commodity chemicals and already using SCADA systems for several years, the savings could be estimated to 1 – 1½ % of operating cost

• For a commodity chemical manufacturer who has just started using SCADA systems, the savings could be at least 1½ -3% of the operating cost

• For a large plant such as Oil Refinery already using SCADA systems for several years, the savings could be estimated to 0.2 – 0.5% of the operating cost

• For a large plant such as Oil Refinery that has just started with SCADA systems, the annual savings could be at least0.5 – 0.8% of the operating cost

ECONOMIC JUSTIFICATIONECONOMIC JUSTIFICATION

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WHAT ARE THE OTHER SAVINGS?WHAT ARE THE OTHER SAVINGS?• If you could deliver the product with better specifications,

and every production unit could be better controlled…What are the savings? Ask yourself

• If you could quickly change to make another product with existing equipment, especially if you need to follow the FDA rules and get the FDA acceptance… What are the savings? Ask yourself

• If you could get a large contract based on better production planning, better documentation, and better product qualityWhat are the savings? Ask yourself

For some it could be 50% savings, and for some 5%. We believe 10% of savings first year will return many times the investment in CHEMCAD and the SCADA integration